Control of flash butt welders



June 22, 1948. M. M. SEELOFF CONTROL OF FLASH BUTT WELDERS Filed Feb. 5, 1945 MELVIN M SEELOFF Patented June 22, 1948 CONTROL OF FLASH BUTT WELDERS Melvin M. Seeloff, Warren, Ohio, assignor to The Taylor-Winfield Corporation, Warren, Ohio, a

corporation of Ohio Application February 3, 1945, Serial No. 575,971

12 Claims.

This invention relates to electric resistance welding apparatus and more particularly to improved arrangements in such apparatus for moving the work pieces and/ or electrodes relative to each other. In flash-butt welding machines particularly it is highly desirable to employ a platen moving and force applying device which is smooth inoperation yet highly sensitive to variations in controlling reference conditions whereby the device may be utilized to effect optimum continuing flashing conditions under either manual or automatic control. In such apparatus it is desirable that all backlash in the drive be eliminated to avoid erratic forward movement of the platen particularly during flashing and to avoid any de- I lay in changes in the character of movement of the platen in response to any variation in the controlling reference condition. In spot and seam welding apparatus it is desirable that the means employed to move and apply welding force to the electrodes be capable of precise and instantaneous control whereby the welding force may be readily controlled and that if it is desired to increase the welding force during the welding cycle such increase may be quickly effected without the normally attendant surging action of any of the movable parts of the assembly.

The above objects are accomplished by the present invention by employing a double acting fluid motor for effecting relative movement between the work pieces and/or welding electrodes and for applying the welding forces therethrough, maintaining both opposing chambers of the m0- tor filled with fluid under pressure substantially at all times, and proportioning a fluid stream impinging against ports leading to said chambers. Further, sensitive air-balanced relay means may be used to determine the position of said stream whereby the element driven by said motor may be made to move or to vary the force transmitted quickly and accurately in response to changes in some reference condition.

A further and more specific object of the invention is the provision in a flash-butt welder of an improved system for governing the relative movement of the work pieces during the flashing period whereby such movement may be made automatically responsive to flashing conditions and whereby the apparatus required for such operation is substantially simplified.

The above and other objects and advantages of the invention will become apparent upon consideration of the following detailed specification and the accompanying drawing wherein there is distil closed a representative embodiment of the invention.

The single figure of the drawing is a schematic representation of an electric resistance flash Welding machine constructed according to the principles of the invention.

Referring to the drawing, reference numerals ill and ii represent normally fixed and movable platens, respectively, of an electric resistance flash-butt welding machine and, in accordance with usual practice, each platen is provided with a stock clam-p l2 to hold the stock pieces in proper position for welding. Suitable electrodes are provided to conduct welding current to the clamped stock pieces and, as shown, such electrodes are electrically connected to the secondary of a welding transformer l3. The primary of transformer I3 is arranged to be energized from a suitable current source comprising the line conductors LI and L2. Interposed in the supply circuit leading to the transformer I3 is a control system, shown schematically at M, the normal functions of which :are the control of the strength of current both during flashing and during upset and the cutting off of the cur-rent upon completion of the upsetting operation. While the details of the system l4 form no part of the present invention, the same is preferably of the kind employing electronic switching devices and adjustable phase shifting circuits to control the conduction in the devices.

Movable platen l l is arranged to be moved by a piston contained within a double acting cylinder l5. A conduit [6 leads to the rod end of cylinder l5 while a second conduit ll leads tothe opposite end thereof. At their inlet ends the passages through conduits l6 and H are brought into close proximity with each other, being separated by a knife-like wall l8. A rapidly moving stream of fluid under pressure, preferably hydraulic fluid, is directed against the inlets of the conduits l6 and H by a jet-tube I9 having a nozzle .20 positioned adjacent the outer edge of dividing wall 18. Tube [9 is pivotally mounted at 2| and it should be apparent that the direction and speed of movement of the piston in cylinder l5 will be dependent on the position of the tube 19. If tube I9 is so moved as to move nozzle 20 to the right a greater pressure will be built up in the head end of cylinder 15 and consequently the piston and platen II will be moved to the leftthe speed of such resulting movement being determined by the pressure differential in opposite ends of the cylinder. The greater the movement of tube [9 the greater will be this pressure differential.

It should be observed, however, that the arrangement insures the continuance of fluid pressure in both ends of the cylinder and insures a smooth transition from equalized to unbalanced pressures and vice versa so that the resulting movement of platen ll will be uniformly smooth which is an especially desirable characteristic in flash welder operation.

Fluid under pressure is supplied to the tube :9 by a conduit 22 leading from a suitable source 23.

To provide for the abrupt movement of the platen as i required at time of upset, I employadditional and larger conduits leading to eitherend of the cylinder l5 from a valve 24. Valve '24 is arranged to be actuated by a solenoid 25 which derives its operating energy from a circuit including the current source 21 and the switches 2t and 26 all in series. Valve 24 is provided with an inlet port having a conduit connection with an accumulator 28 arranged to be charged from the sou-roe 23. Valve M is also provided with an outlet or discharge port and the nature of the valve is such that when solenoid 25 is de-energized all the ports are blocked but when solenoid 25 is energized the inlet port communicates with the port leading to the head end of cylinder while the port in communioation with the rod end of the cylinder i5 is connected to the discharge port. In this manner the valve 2'4, when not actuated, cannot interfere with the control of the-movement of the piston in cylinder: l5 by the position of tube It and, when actuated, is operative to effect abrupt forward -movement of the platen l l irrespective of the position of the tube l9. It should be understood,

of course, thatthe openings in conduits l6 and ll 11'! are much smaller than the openings in valve 24 and-in the conduits interconnecting valve 24 with cylinder it so that the leakage through conduits Iiiand li will have little effect upon the movement of the piston upon dumping of the charge in -the=accumulator 28 by the valve 24.

As indicated, switch '26 is actuated in response 'to forward movement of the platen H and, in

practice, the operating point of switch 26 had- 'justable so that the extent of burn-off of the stock before upset may be controlled. Switch "26 is manually operated and normally closed and is provided for the purpose of releasing solenoid thereby allowing fluid issuing from tube l9 to retract platen l'i followin completion of a welding cycle.

l'Iub'e I9 is swung about pivot 2! by an'actuating rod 29 Which is biased to the left by a spring 30 and to the right by fluid pressure (preferably air) contained within a bellows 3|. Fluid under pressure is' furnished: the bellows 3| from a suitable source 33 through a pressure regulating valve 34, a restricting orifice 35, and conduit 32. The pressure in conduit 32 andconsequentl in bellows 31, however, is controlled by a movablev valve 31 covering a bleeder port 36 leading from the conduit 32. It should be apparent thatif valve 3'! is closed pressure will build up in bellows 3| tomove tube f9 to the right thereby moving platen H .in a forward direction. Upon the valve 37 withdrawing from port336 the pressure in bellows 3i. drops and tube IQmoves to the left .to slow down, arrest or reversethe movement of .plate'n ll depending onthe extent of opening-of valve 31. Thus, tube l8 floats within a fairly narrow range of movement with the median of such range coinciding with the outer edge of Wall I3.

While it is within the contemplation of'this :invention'that the relay control as represented Jbythe valve :37 may be actuated. mechanically,

electrically, or manually, and in accordance with a predetermined time-position pattern or otherwise, I preferably utilize the control instrumentalities thus far described to govern the movement of the platen l l in accordance with instantaneous flashing conditions whereby continuing optimum flashing action may be automatically effected. 'ThusI may govern the movement of the platen H in accordance with an electrical condition of the work cleft or in accordance with current conditions in the primary circuit of the welding transformer which reflect the condition of the arc. If the arc tends to extinguish, the secondary circuit resistance rises and less primarycurrent is drawn whereas if the flashing work pieces approach each other too closely excessive cur-rent is drawn. In the system illustrated the movement of platen I I is so controlled t-h'at optimum arc length as determined b pri- .a solenoid -39 tending torock beam 38 in a direction to close valve 31. To the opposite end of beam 38 is connected 2. depending dampening vane immersed in an oil bath 40. Thus the pull of solenoid 39 is balanced against the force created by the air issuing. from the port 36 although it should be understood that a balanced valve structure may be substituted for the ports 3t, 3'; and other means, as additional weight on the dampening vane, may then be employed to oppose the pull of solenoid 39. Solenoid 391s controllably ener ized from a current supply line Chi, leading from the principal source LI, L2,

. through a circuit including conductors 4|, 42, 44

and :a controlled gaseous discharge device 43. The latter serves not only as a means for modulating the strength of current furnished the solenoid 39 but also as a means for rectifying this energizing current.

Conduction in. tube '43 is controlled by a circuit which maybe traced from the cathode of the tube through conductor to adjustable tap A on resistor 16, the upper. portion of resistor 46, resistor 41, conductor 48, secondary 49 of a phase shifting transformer 59, and current limiting resistor 5l to the control grid of tube 43. The biasing component thus furnished by the voltage drop acrossthe upper portion of resistor 46 is positive, it being observed that a potential is normally maintained on resistor by a rectifier 52 drawing current from the line CL! through transformer "53. A filter 54 smoothes the output of rectifier 52. The potential drop across resistorllw'hich outlined, is detcrminedby conduction in the controlled space discharge device '55 the anode of which is connected to conductor "48' while the cathode is connected to an adjustable tap B on resistor 43. Since point B is more negative than point A the vpotential.developed across resistor '41 can approach and exceed the drop across the upper portion of resistor 46 in which case tube 43 I ill pass' less and less current and, if necessary, be driven -to-cut-oif. The output cf transf-ormer 5B isdelayed approximately =electrical degrees with. respect to: the voltage "wave in line. CL I Conduction in tube-5'5 ma be made'responsive to flashing conditions at the W'elder'and as explained above, SIlChI'COl'ldlillOl'lS may 'bessens'ed-r by determining the strength "of current iiowingxrin the :primary winding of. the welding. transformer.

is applied to the control grid Accordingly, I provide a resistor 51 in the grid circuit of tube 55 and develop across this resistor 51 a potential proportionate to the stren of the primary current. Such grid circuit may be traced from the cathode of tube 55 through adjustable tap B, the lower portion of resistor 45 (providing a negative component), conductor 56, resistor 51, conductor 58, and a suitable current limiting resistor to the control grid of tube 55. Resistor 51 is connected across the output of a rectifier 6E3 the input of which is connected to the secondary winding of a current transformer 59 which has as its primary a conductor leading to one of the terminals of the primary of the welding transformer.

i In flash-butt welding apparatus it is frequently desirable to automatically reduce the voltage applied to the welding transformer upon completion of the flashing or at point of upset and to cut off the welding current entirely upon completion of upset, These functions may be accomplished by the circuits ii263 and 62-454, respectively, which are closed in sequence by the switch 6! having an operating member carried by the platen H and which are connected into the control assembly Hi. In practice, switch 6! is adjustable to compensate for variations in length of burn-off and upset, It should be understood that assembly l4 will be provided with suitable ;phase shifting circuits or other suitable control arrangements whereby may be first reduced and finally cut off in accordance with requirements.

; Shunted across tube 55 is a normally closed switch 65 so that normally the potential of tap B of tube 43 to hold the latter non-conducting. This allows valve 3631 to remain open and the spring 30 to hold jet 2U opposite the entrance to conduit It. The platen H is thus retained in retracted position. When it is desired to make a weld the work pieces are clamped in the platens Ill and H and the control 14 is adjusted for the proper heat required for the work at hand and the switch 65 is opened. Immediately tube 43 is conditioned for maximum conduction to energize solenoid 39 and close Valve 35- 31 whereby pressure builds up in bellows 3! to shift tube IE! to the right thereby admitting fluid into the head end of cylinder I5 to advance platen ll.- As the arc is struck, current begins to flow in conductor 12 and, modulated in accordance with the strength of this current, is the positive component of biasing potential developed across resistor 51. Tube 55 begins to conduct at a corresponding rateto modulate the output of tube 43 in the manner described above. A sensitive balance is thus established at the valve 35-41 and the following action of the jet tube controls the movement of platen H to maintain optimum flashing conditions. For example, if the arc becomes too short or if the work piecescontact each other excessive current flows in conductor L2 to drive the control electrode of tube 43 highly negative thereby slowing or interrupting forward movement of platen H or even reversing such movement as the needs dictate. The flashing continues under such automatic control until the desired amount of material is burned off the work pieces at which time, switch 26 is closed to dump the fluid in accumulator 28 into the head end of cylinder 28 to effect a quick upsetting movement of the platen I l. Simultaneously circuit 62-63 is closed to reduce the voltage applied to the welding transformer and, of course,

the welding current upon actuation of valve 24 the position of jet tube [9 has little or no effect on the operation of cylinder [5.

Upon completion of upset, switch 6| closes circuit 62-454 to interrupt entirely the flow of current in the primary of the welding transformer. The work pieces may now be unclamped and by depressing switch 26 valve 24 re-centers to allow fluid issuing from jet 26 to retract the platen H, The machine is thus recycled preparatory to the next succeeding welding operation.

The above specifically described embodiment of the invention should be considered as illustrative only as obviously many changes may be made therein without departing from the spirit, or scope of the invention. For example, the open jet proportioning means i8, 20 may be readily replaced with an enclosed proportioning valve and, as explained above, the disk valve 36, 31 may readily be replaced by a balanced valve preferably of the spool type as will be understood.

The particular control mechanism connected to the air bleeder or pilot valve will be determined primarily by the nature of the control it is desired to exercise over the movement of the platen particularly during flashing. Such control may be manual in which case the pilot valve may be mounted directly on the platen and a direct manually engageable operating lever provided, electrical of which the present detailed embodiment is representative, or mechanical wherein a time controlled cam may be employed to actuate the pilot valve. Also, as explained above, various features of the invention are applicable to electric resistance welding systems of the spot and seam welding types. Reference should therefore be had to the appended claims in determining the scope of the invention.

What I claim is:

1. In electric flash welding apparatus having a normally fixed work holding platen and a movable work holding platen as well as a welding transformer having its secondary adapted to be electrically connected to the work pieces held in said platens; the combination of means to move said movable platen comprising a double acting cylinder having a piston connected to said movable platen, conduits having adjacent inlet ports to conduct fluid under pressure into opposite ends of said cylinder, a movable jet-tube having its discharge end positioned opposite said inlet ports whereby fluid under pressure is supplied to said ports in proportions determinedby the position of said jet-tube whereby the direction and speed of movement of said movable platen may be controlled, and means to conduct fluid under pressure into the opposite end of said jet-tube.

2. In electric flash welding apparatus having a normally fixed work holding platen and a movable work holding platen as well as a welding transformer having its secondary adapted to be electrically connected to the work pieces held in said platens; the combination of means to move said movable platen either toward or away from said normally fixed platen comprising a double acting fluid pressure motor having a pair of opposed expansible chambers each having an inlet port, said inlet ports being adjacent to each other, means to deliver an impinging stream of fluid against said ports, and means to change the alignment of said stream with respect to said ports whereby the relative pressures in said chambers maybe controlled to control the movement of said movable platen.

3. In electric flash welding apparatus having means to condiret welding current tontne work pieces' to be welded; means: to move s-aid world pieces relative to each other comprising al -double acting fluid "motorhaving a pair lof opposed- 1 expansible chambers: each having an inlet" port; said ports "bein'g 'adja'cen't to eachothcr; me'a-mto; deliver an impinging stream of fluid against said ports;- and f means to change the alignment of sa'idstream with respect to'said' ports whereby the'=relative" pressures in'said chambers-may be controlled" cornmisin'g an air motor; a movable control member; and a ble eder valve operated by said control-member in control of the" operation of said air motor.

4; In electric"- flash i w elding apparatus 5 having" means-to conduct welding: current to the Work" pi'eces tobe' welded, means t'o move said" work pieces relative' to I each other coniprisliI-Ig a double acting fluid 'motor having a' pa'ir of opbosed expansiible chambers each h'av inlt port, means establi'shirrg a fluid-stream; a nd means -to proportion said stream between said 'ports wherebylthe relative pressures in sa id chambers and consequently th'erclative mtweniento'f-"said work' pieces may be controlled-.-'

5*." In electric flash" welding apparatus having means toconduet' weldifig current 1 to the work" pieces to be welded, means -to move" said W'Ork'" pieee'srelative t"each' other colrnprising adouble aeting' fiuid m'ot'orhaving-"a pair of 'oppesed ex pansible chambers each having an inlet port,- means establishing a fluid stream; and meansmovable automatically in"- response toflashing lcon-dtions to proportion saids-ti'eam b-etweemsaid ports whereby the relativemovement 'of said work ieces may be controlled insuch-manner to automatically maintain optimum fiashing condition.

6. In electric flash welding apparatus having means-teconduct welding current to the Work pieces to -b'ewelded, means temovesaid work pieces toward each' oth'ercomprisin'g an expansible chamb'er 'flui'd motonhavlng an inlet port, meansestab1ish'inga fluid stream? a movablen i'e'rnber' to" determine the proportion of said.- stream imnin'ging against said" port; and means to cont'rol the movement of said member comprising" a solenoid and-means to v'ary the energization' of said solen'oid in accordance with fluetuati-ons' in the weldingcurrent.

'71 In'electricflash welding" apparatus j having means to conduct welding currentxtothe work pieces to be welded and means to movesaid' work pieces relative toeach'other; the combination of a solenoidin control "of said meansto move; and means to vary the en'ergization of said solenoid in accordance with fluctuations lathe-welding current-during the flashing period.

8; Inelectri'c resistance welding apparatus hav mgwelatively movable electrodes and means to conduct welding currentto said electrodes: the

combination of means toefi'ct relative movement Q'AKEEQBE to' 'cont'rol said last Inentionedmeans.

9.-In electric resistance welding apparatus h'aV ing relatively movable electrodes and means we conduct weldingcurrent to said electrodes; the combination of means toefiect'rlativ move-- i ment :between said electrodes comprising a doubl" acting fluid motor having apairof op posede'xpanslble chambers, means to conduct the flifid under pressure intoeach of said chambers+-ln+' eluding a valve to proportion the'fl'ow of mm relative-to said-chambers, an air n'u'mtor ir'r control of'theho per ation of said valve, and a-pilot valve in" control of theoperation o-fsaidairmotor;

10. Apparatus according to clain'rQ further-1n eluding a -sol'en'oid 'for operating said pilot valve;

- and m'eans to" energize said solenoidm response to variations in the current conducted by said electrodes.

11; In electric resistance having relatively movable welding apparatus work engaging" elec trodes'a'nd means toconductweldingcurrent'to sa id electrodes; the combination" of means tb efiect relative movement between said electrodescomprising a fluid motor having an-expansible chamber andbeing operative upon admission 0t fluid under pressure into said chamber to'n'iov'e said electrodes relatively toward each othergan inlet port to sa-idchamb'er, means'establishing-ia" fiuid streamnnder pressure, and means "to varythe degree" of "coincidence by --the saiiwstream and said" port, whereby the effective pressure *in' sa'ld' chamber may be controlled.

12. Apparatus'according to claim 11' further characterized in that said mean's'to vary inlciudes asolenoid; and means to control the encrgizatio'r'i of said solenoid in accordance with variatlohsifl the current flowing th'nough said electrodes};

MELVIN MI SEELOFFQ REFERENCES CITED The following references are o'f'recorddn' the file of'this'pat'entf UNITED- STATES PATENTS Number Name" K Date v 1,5e2;204* Carlst'ed't' N v. 17,1925; 1,957,759" Coates et al ay a; 193 p 1,983,781- Shippy Dec. 11, 1934f 2,089,213 Labodle" Aug 10, 1937" FOREIGN PATENTS N umber Country Date I 7 280,659 Great-Britain NOW '24, 1927'" 

